Multi-sensor analysis and data point correlation for predictive monitoring and maintenance of a pressurized fluid cutting system

ABSTRACT

A method and system utilizing multi-sensor analysis and data point correlation is provided for predictive monitoring and maintenance of a pressurized fluid cutting system. In a disclosed aspect, multiple sensed characteristics of system operation are correlated to determine a particular failure mode. Identification of the failure mode through active sensor data analysis and correlation facilitates predictive maintenance, minimizes system downtime, and optimizes system output.

CROSS-REFERENCE TO RELATED APPLICATIONS INCORPORATED BY REFERENCE

The present application is a continuation of U.S. patent application Ser. No. 16/135,567, titled MULTI-SENSOR ANALYSIS AND DATA POINT CORRELATION FOR PREDICTIVE MONITORING AND MAINTENANCE OF A PRESSURIZED FLUID CUTTING SYSTEM, which was filed on Sep. 19, 2018, and is incorporated herein by reference in its entirety.

BACKGROUND Technical Field

This disclosure relates generally to maintenance of pressurized fluid cutting systems and more particularly to multi-sensor analysis and data point correlation for predictive monitoring and maintenance of a pressurized fluid cutting system.

State of the Art

Components of pressurized fluid cutting systems, such as waterjet cutting systems, often fail or wear out and need to be replaced to maintain operability of the cutting systems. Various components have different life durations and parts can, at times, fail with little warning. Some components, such as nozzles and orifices may only last a few hours, while other components, such as check valves, cylinders and seals may last hundreds of hours. The lifespan of each component is somewhat dependent on the conditions a cutting system is being operated at, where, in general, components in systems operating at lower pressures will fail less frequently than those in systems operating at higher pressures, but that is not always the case. When a component fails the cutting system typically must be stopped and the component repaired or replaced. This results in costly down time (lost operational output and monetary revenue) and maintenance costs (a pressurized fluid cutting system can take many hours to disassemble and reassemble). The costs associated with down time and maintenance are often much higher than the cost of the component itself. When a cutting system fails or begins to operate inefficiently, it may be difficult to determine which specific component(s) are responsible for the failure or decreased operability of the system, thus requiring extensive diagnostic procedures to find the failed component(s). Diagnostic procedures further add to the maintenance cost and downtime financial losses of the cutting system operator.

As a result of the high maintenance costs/man hours and unpredictability of component failure associated with pressurized fluid cutting systems, many operators track hours of use of the various components and, in the event of a failure, frequently choose to replace not only the failed component(s) but several other components which may still have significant amounts of useable life remaining, so as to avoid having to incur further maintenance costs at a later date (essentially a form of preventative maintenance). Hence, there is a need for active diagnostics facilitated by multi-sensor input, analysis and data point correlations for predictive monitoring and maintenance of a pressurized fluid cutting system, to accurately predict a specific impending failure or diagnose a specific root cause of a failure, to thereby optimize service and replacement of pressurized fluid cutting system parts and to minimize downtime.

SUMMARY

An aspect of the present disclosure provides a method of identifying a failing component in an operating pressurized fluid cutting system, the method comprising: actively sensing a first characteristic of the pressurized fluid cutting system and gathering data pertaining to the sensed first characteristic; actively sensing a second characteristic of the pressurized fluid cutting system and gathering data pertaining to the sensed second characteristic; analyzing the data associated with the sensed first characteristic and the sensed second characteristic; and identifying a failing component based upon the analysis of the data associated with the sensed first and second characteristics.

Another aspect of the present disclosure provides a method of identifying a failing component in a pressurized fluid cutting system, the method comprising: sensing a first characteristic of the pressurized fluid cutting system using a first measurement methodology; sensing a second characteristic of the fluid cutting system using a second measurement methodology; and correlating the sensing of the first characteristic and the sensing of the second characteristic to the identification of a failing component of the pressurized fluid cutting system.

Still another aspect of the present disclosure provides a system for identifying a failing part of a fluid cutting system, comprising: a computer; a first sensor in electrical communication with the computer and configured to sense a first characteristic of a fluid cutting system; a second sensor in electrical communication with the computer and configured to sense a second characteristic of the fluid cutting system; and a user interface in communication with the computer and configured to display indicia of a failing part, wherein the indicia of the failing part is generated by correlating a first sensed characteristic of the fluid cutting system with a second sensed characteristic of the fluid cutting system to identify the failing part by the computer.

The foregoing and other features, advantages, and construction of the present disclosure will be more readily apparent and fully appreciated from the following more detailed description of the particular embodiments, taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members:

FIG. 1 is an embodiment of a common prior art decision tree diagnostic model utilized in the pressurized fluid cutting system field, in accordance with the present disclosure;

FIG. 2 is a schematic diagram of an embodiment of a pressurized fluid cutting system operable with a sensor-based diagnostics system having sensors disposed near cutting system components to monitor operations and help predict component failure(s), in accordance with the present disclosure; and

FIG. 3 is a schematic diagram of an embodiment of a correlations table visually depicting sensed pressurized fluid cutting system characteristics, in accordance with the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

A detailed description of the hereinafter described embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures listed above. Although certain embodiments are shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present disclosure will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as an example of embodiments of the present disclosure.

As a preface to the detailed description, it should be noted that, as used in this specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise.

Referring to the drawings, FIG. 1 depicts an embodiment of a common prior art decision tree diagnostic model 10 utilized in the pressurized fluid cutting system field. A common technique for detecting potential problems with pressurized fluid cutting systems involves technicians passively monitoring cutting system operations looking for characteristics such as overstroke and/or distinct temperature changes of the pump output to give clues, after a system failure, as to which component(s) may have significantly deteriorated or completely failed. However, in utilizing passively perceived data points the technicians are merely reacting retroactively to a failure and are simply narrowing the list of potential failed components rather than actually diagnosing the real issue. An example of such retroactive diagnosis and response is depicted schematically in FIG. 1, which shows a common decision-making/troubleshooting tree 20 that a technician may progress through, via experience-based trial and error (or luck), to ultimately identify the failed component(s) and commence an appropriate remedy after the system failure. The common approach recognizes that, in addressing a component failure, elimination of the principal failure mode typically renders the most efficient return to optimal system performance. However, sometimes the operator progresses far down the decision tree 20 before the failure is accurately diagnosed. For example, an operator may notice a characteristic 22 of operation that is different than normal. From experience, the operator may note that such an anomaly characteristic 22 often is a result of known component and/or system failure. Hence, the operator may set out to diagnose the true cause of the failure by iteratively examining components and/or systems known to potentially be associated with such an anomaly characteristic 22, in an attempt to narrow down the list of potential failed components. Sometimes the operator identifies the problem after examining only one or a few components and/or systems. Yet, in other instances, the operator may move far down the decision tree 20 ruling out potential sources of the failure, until the true failed component 25 is discovered, as is shown in FIG. 1. Such iterative diagnostics performed in reaction to anomalistic characteristics 22 manifest due to system failure can be costly because of the extended downtime often associated with diagnosing and repairing/replacing the failed component or system.

Once a failed component 25 is finally identified, through the use of common diagnostic practices, then the operator may determine whether the component is part of an assembly or system and whether known failure tendencies of the assembly or system may warrant replacement of additional components. If replacement of the additional components is warranted, then the additional components may also be replaced during the same period during which the identified failed component 25 is replaced, to minimize downtime. For instance, as further exemplified in FIG. 1, an operator may march through the decision tree 20, following realization of an anomaly characteristic 22, to iteratively diagnose system health and identify a failed component 25. It may be determined that the failed component 25 is a high pressure seal 64 a. The operator may input particulars regarding the discovered the failure into a computer 50 associated with the pressurized fluid cutting system. It may be determined that the failed high pressure seal 64 a is part of a high pressure cylinder assembly 60, wherein the high pressure cylinder assembly includes two high pressure seals 64 a-64 b, two seal hoops 62 a-62 b, two O-ring seals 66 a-66 b, a back-up sleeve 67, and a high pressure cylinder 68. From experience and past operation history (which operation history may possibly be stored in the memory of the computer 50) it may determined that it would be beneficial to replace not only the failed high pressure seal 64 a, but to replace all the components of the entire high pressure cylinder assembly 60, to help ensure proper functioning of the components and prevent potential future downtime should any of the components fail in the near future if not immediately replaced. In other words, often it is cheaper to replace components that may fail soon rather than experience additional downtime to replace them later if necessary.

The imprecise passive failure determination techniques and extended/costly downtime of typical pressurized fluid cutting systems associated with common diagnostic methodology are problematic. The present disclosure sets forth vastly more efficient solutions. With further reference to the drawings, FIG. 2 depicts a schematic diagram of an embodiment of a pressurized fluid cutting system 100 operable with a sensor-based diagnostics system 400 having sensors disposed near cutting system components to monitor operations and help predict component failure(s). Embodiments of the sensor-based diagnostics system 400 may comprise various structural and functional components that complement one another to provide the unique functionality and performance of the actively monitored and predictively diagnosed and maintained pressurized fluid cutting system 100, the structure and function of which will be described in greater detail herein.

As depicted schematically in FIG. 2, an embodiment of a pressurized fluid cutting system 100 may include a low pressure fluid reservoir 110, such as a holding tank, to store, or otherwise hold and/or provide an accumulation of fluid 101, such as water, that will be pressurized and utilized for cutting. The fluid 101 from the low pressure fluid reservoir 110 is in communication with a pump 120. The pump 120 is in fluid communication with an intensifier 130. The intensifier 130 is operable with an accumulator 140, controls 150, and a hydraulic unit 160, which are all working to increase the pressure of the fluid 101 and deliver the high pressure fluid to a valve 170. The valve 170 permits passage of pressurized fluid 101 into a nozzle unit 190 where it may be combined with an abrasive 102. The abrasive 102 may originate from an abrasive tank 180 where it is stored and readied for provision to the nozzle unit 190. The nozzle 190 directs a pressurized fluid cutting jet 103 toward a workpiece 300. The workpiece 300 is cut by the pressurized fluid cutting jet 103 and the fluid 101 and potential abrasive 102 comprising the cutting jet 103 then enters a drain and catcher 115, where the fluid 101 and potential abrasive 102 is prepared for either disposal or future recycled use. Those having ordinary skill in the pertinent art will recognize that the schematic depicted in FIG. 2 is merely exemplary and various known component parts, systems and features of a pressurized fluid cutting system may not be shown. Rather, the schematic sets forth common component elements of a pressurized fluid cutting system 100, to show how a sensor-based diagnostics system 400 may be incorporated therewith.

As further depicted in FIG. 2, an embodiment of a pressurized fluid cutting system 100 may be operable with a sensor-based diagnostics system 400 having sensors disposed near cutting system components to monitor operations and help predict component failure(s). The sensor-based diagnostics system 400 may be incorporated with, attached to, or otherwise be a structural and/or functional part of the pressurized fluid cutting system 100. Various types of sensors may be included in the sensor-based diagnostics system 400, such as vibration sensors v, temperature sensors t, pressure sensors p, audio sensors a, stroke sensors s, leak sensors Lk, and other like sensors operable for detecting pressurized fluid system operational characteristics and providing data regarding the same.

The various sensors of a sensor-based diagnostics system 400, such as sensors v, t, p, a, s and Lk, may be mounted on, connected to, or otherwise disposed near pressurized fluid system 100 components/systems. For example, a leak sensor 410Lk may be disposed in an appropriate location near the low pressure fluid reservoir to monitor whether the reservoir is leaking fluid, such as low pressure water. Moreover, several sensors, such as an audible sensor 420 a, a vibration sensor 420 v, a pressure sensor 420 p, a temperature sensor 420 t, a stroke rate sensor 420 s and a leak sensor 420Lk, or other like sensors, may be mounted on or otherwise disposed in appropriate locations near the pump 120. Similarly, several sensors such as an audible sensor 430 a, a vibration sensor 430 v, a pressure sensor 430 p, a temperature sensor 430 t, a stroke rate sensor 430 s and a leak sensor 430Lk, or other like sensors, may be mounted on or otherwise disposed in appropriate locations near the intensifier 130. Likewise, additional sensors, such as an audible sensor 440 a, a pressure sensor 440 p, a temperature sensor 440 t and a leak sensor 440Lk, or other like sensors, may be mounted on or otherwise disposed in appropriate locations near the accumulator 140. Furthermore, sensors, such as an audible sensor 460 a, a vibration sensor 460 v, a pressure sensor 460 p, a temperature sensor 460 t, a stroke rate sensor 460 s and a leak sensor 460Lk, or other like sensors, may be mounted on or otherwise disposed in appropriate locations near the hydraulic unit 160. Still further, several sensors, such as an audible sensor 470 a, a vibration sensor 470 v, a pressure sensor 470 p, a temperature sensor 470 t, and a leak sensor 470Lk, or other like sensors, may be mounted on or otherwise disposed in appropriate locations near the valve 170. A sensor, such as leak sensor 480Lk, may be mounted on or otherwise disposed in appropriate locations near the abrasive tank 180, to determine whether any abrasive is leaking. In a similar manner to what has been described herein, several sensors, such as an audible sensor 490 a, a vibration sensor 490 v, a pressure sensor 490 p, a temperature sensor 490 t, and a leak sensor 420Lk, or other like sensors, may be mounted on or otherwise disposed in appropriate locations near the nozzle 190.

The sensors operational with a sensor-based diagnostics system 400 may be in electrical or electromagnetic communication with a computer, such as computer 50. The communication between the sensors and the computer may be effectuated via signals passed through electrical wires connecting the sensors and the computer, or may be effectuated via wireless communication protocols. The communication means are shown schematically in FIG. 2 as dashed lines. Moreover, the sensors may be in communication with each other, and input from one sensor may affect operational functionality of sensors it is in communication with. It should be appreciated that many of the same types of sensors may be mounted on or otherwise disposed near pressurized fluid cutting system components and/or systems. For instance, there may be several pressure sensors 430 p disposed to detect pressure characteristics of an intensifier 130. The sensors may monitor, in real-time or near real-time, the operational characteristics of a pressurized fluid cutting system 100 and may provide active input regarding system functionality to the communicatively interconnected computer 50. The computer 50 may include or otherwise be in communication with common user interfaces, such as a keyboard, a screen, a touch-panel monitor, and/or a mouse, so that an operator may utilize the computer 50 to see, review, analyze, extract, transmit, store, correlate and/or input data received from the sensors and act upon any related indicia representative of the data in any operable way.

Embodiments of a sensor-based diagnostics system 400 may facilitate active monitoring and analysis of pressurized fluid cutting system 100 performance and may correspondingly facilitate prediction of time duration extending into the future until complete component/system failure(s). The failure prediction may correspond to days, hours, minutes and/or seconds forecast to transpire in advance of a potential failure of a specific component or system of a pressurized fluid cutting system 100. The active failure prediction capability may enable operators to anticipate and proactively react to an impending component failure (e.g., schedule operations/jobs, perform preventative maintenance, replace aging components in scheduled and optimized downtime periods, and perform manual inspections only accomplishable during system downtime, etc.). In one embodiment of a sensor-based active diagnostics system 400, a combination of temperature, proximity, and drip/leak sensors may be utilized to indicate an upcoming failure of specific component(s). By interpreting/analyzing data from these multiple sensors the system 400 may be able to specifically identify what component or components may be approaching failure and instigate automated/associated prevention/reaction processes or allow an operator to prevent/react accordingly.

As shown schematically in FIG. 2, a number of sensors may be located along the fluid path through the pressurized fluid cutting system 100 and communicatively connected to key components of the system 100. During operation these sensors, such as pressure sensors p, temperature sensors t, audio sensors a, stroke rate sensors s, vibration sensors v, drip/leak sensors Lk, and/or other like sensors may actively monitor the performance and conditions of applicable components and track changes in conditions or behavior in the pressurized fluid cutting system 100. Sensing may be simultaneously effectuated at different locations within the pressurized fluid cutting system 100. Embodiments of an active sensor-based diagnostics system 400 may, for example recognize a temperature rise in the fluid at a certain location within the pressurized fluid cutting system 100, which temperature rise may indicate an impending failure of corresponding system 100 components. As a temperature sensor t actively detects the temperature rise, the sensor-based diagnostics system will begin processing other signals/sensors of the system 400 to identify what the failure mode will be (e.g., which components are likely approaching failure) and select from among the likely components which one will actually fail based upon data gathered from multiple sensors throughout the pressurized fluid cutting system 100. In some embodiments the sensor-based diagnostics system 400 may actively compare and contrast readings from various applicably-related sensors with each other to anticipate and/or interpret potential failures. This compare and contrast analysis is correlative between all actively available sensor input and may further include correlatively looking back into previously collected to data (e.g., historical data or system standards) to analyze the actively sensed behavior and correspondingly predict any potential failure.

In another example of sensor-based active diagnostics, as sensor, such as an audio sensor a, may be disposed in the system 100 and may detect a pump whistling sound—in the current state of the art, tribal knowledge (the technician in the industry today) would likely conclude that the whistling sound is caused by a poppet, which is failing/approaching failure as the chatter of poppet's parts resonate and emit an audible whistle; thus in the current state of the art the poppet would most likely be designated for replacement, when such a whistling sound is heard. Notably however, as shown in FIG. 1, typical trial-and-error type diagnostics are not only reactive (meaning the operating technician likely would not take any action until the audible whistle is so loud that failure has already occurred), but frequently do not yield accurate determinations of failure source until many iterative examinations are performed.

In contrast, an active sensor-based diagnostics system 400 utilizes a plurality of sensors and corresponding readings that may be checked in near real-time and correlated against the audio detection signal. For example, other sensors, such as temperature sensors t, may be disposed about the pressurized fluid cutting system 100, and the signal outputs of all of other sensors, including the temperature sensors t, may be correlatively compared against actively sensed functional characteristics of other pressurized fluid cutting system components, such as another pump or an intensifier component, and also against expected values (potentially stored in the memory of communicatively connector computer 50) for the input operational conditions. The active sensor-based diagnostics system 400 may identify that a center section of a pump is about ten degrees warmer than expected. This determination may correlatively prompt the diagnostics system 400 to then analyze data for the last 50 days of operation for this specific pump system. In the disclosed example, it could be that the diagnostics system identifies that 10 days prior to the audio signal (whistling being detected by an audio sensor a) the center section temperature went up 10 degrees and stabilized. By comparing the correlated results and analysis against the stored historical data, the diagnostics system 400 may be able to determine that the initially suspected poppet is an incorrect fix. Rather, through active sensing and correlated diagnostics, the system 400 may determine that T-seals in a piston that holds a plunger are approaching/beginning to fail and should be replaced. Such an active diagnostic analysis allows the system 400 to predict potential failure before it occurs.

With further reference to the drawings, FIG. 3 depicts a schematic diagram of an embodiment of a correlations table 500 visually depicting sensed pressurized fluid cutting system 100 characteristics. The sensors and associated signals used and analyzed by embodiments of a sensor-based diagnostics system 400 may include any number of sensors located about the pressurized fluid cutting system 100 and the table may facilitate charted functional characteristic associations. Such sensors may include audio, vibration, temperature, pressure, stroke rate and drip/leak sensors (a, v, t, p, s, and Lk), and other like sensors. System 100 components the sensors may actively monitor may include check valve bodies, high pressure poppets, high pressure seals, low pressure poppets, high pressure (HP) static seals, high pressure (HP) cylinders, bleed down valves, center sections of pumps and/or intensifier units, on/off valves, cutting heads, high pressure fittings, and many other like components operational with a pressurized fluid cutting system 100. For example, a pressure transducer may disposed on a low pressure water line, a temperature sensor disposed on a high pressure water line (e.g., in an output adapter for a high pressure (HP) poppet), drip/leak detection sensors may be disposed about the system, a temperature sensor may be disposed in, on or near a high pressure cylinder, a stroke rate sensor may disposed in, on or near a pump, and other like sensors etc., may be located and utilized for actively monitoring functional characteristics of component elements and features of a pressurized fluid cutting system 100.

Embodiments of sensor-based diagnostics systems 400 may implement and utilize access to, correlation between, and analysis of the signals from the various multiple sensors, along with stored historical functionality data, to accurately predict specific component failures. Failure prediction may be facilitated by correlating actively sensed characteristics of components of a pressurized fluid cutting system 100. The correlating may comprise identifying sensor readings that are above a threshold value. For instance, a signal from the pressure transducer on a low pressure water line may manifest a reading above a set pressure threshold initially suggesting potential poppet failure. Meanwhile, a signal from a temperature sensor on the high pressure water line may manifest a temperature reading above a set temperature threshold indicating a potential cylinder crack if correlative leakage is detected from applicable drip/leak detection sensors—if there is no leakage then the potential failure source may be, for example, at least one of a set of parts comprising: a low pressure poppet, a check valve body, a seat, or a high pressure poppet. With the presence of a temperature signal and a pressure signal on the low pressure transducer the sensor-based diagnostics system 100 may determine that it is the low pressure poppet that is likely tending toward failure. Moreover, if the stroke rate sensor indicates overstroke then the sensor-based diagnostics system 400 may also determine that there is a failure tendency associated with low pressure poppet. Additionally, if the sensor-based diagnostics system 400 detects a temperature increase signal and no correlative spike in pressure, then it may be determined that at least one of a set of parts comprising the low pressure poppet, the seat, and/or the check valve are tending toward failure. The system may identify a part, such as the low pressure part, is in a first identified set of parts, as well as a second identified set of parts. Thereby revealing greater probability regarding source of a failure mode. An advantage of a sensor-based diagnostics system 400 over common diagnostic practices is that actively-sensed near-real-time system 100 functionality knowledge may help to simplify maintenance and repair procedures, as the operating technician, acting on indicia corresponding to such knowledge, may only have to remove and inspect an outlet portion of the pressurized fluid cutting system 100 to corroborate diagnosed failure modes.

Through the provision and utilization of a multitude of sensors (as schematically depicted, for example, in FIG. 2) and their associated signals and data points correlated between actively monitored characteristics (as schematically depicted, for example in FIG. 3) and historical system functionality, embodiments of a sensor-based diagnostics system 400 may be able to actively monitor the life and operational fitness of components within a pressurized fluid cutting system 100. Such active diagnostic capability may provide system operators and maintenance technicians accurate maintenance predictions and timetables. The readings and signals from a number of sensors disposed about a pressurized fluid cutting system 100 may be set forth as corresponding indicia facilitating visualized prediction of potential near term component failure and operational fitness. In addition, further correlative comparison against historical data points may also help to identify specific component failure tendencies. The computer 50 may perform analysis and correlation of sensed operational characteristics of the pressurized fluid cutting system 100. Sensor-based diagnostics systems 400 may implement measurement methodology, such as acquisition and interpretation of active sensor-monitored/reported component functionality and may implement analytic correlation methodology, such as cross-referencing sensor signals of a plurality of sensors disposed near component elements of a pressurized fluid cutting system 100, to actively determine and verify anticipated component failures in ways not possible through common diagnostic efforts. As a result, system performance may be increased, downtime may be minimized, and output may be optimized.

The components and features defining embodiments of the above-described pressurized fluid cutting system 100 and corresponding sensor-based active diagnostics system 400 may be formed of any of many different types of materials or combinations thereof that can readily be formed into shaped objects provided that the components selected are consistent with the intended operation of pressurized fluid cutting systems 100 and corresponding sensor-based active diagnostics systems 400 of the type disclosed herein. For example, and not limited thereto, the components may be formed of: rubbers (synthetic and/or natural) and/or other like materials; glasses, such as fiberglass, silicate glass, naturally occurring glass, or any other amorphous solid material, any combination thereof, and/or other like materials; ceramics or any other crystalline or partly crystalline material, any combination thereof, and/or other like materials; wood or any other hard, fibrous structural tissue or material, any combination thereof, and/or other like materials; carbon-fiber, aramid-fiber, any combination thereof, and/or other like materials; polymers such as thermoplastics (such as ABS, Fluoropolymers, Polyacetal, Polyamide; Polycarbonate, Polyethylene, Polysulfone, and/or the like), thermosets (such as Epoxy, Phenolic Resin, Polyimide, Polyurethane, Silicone, and/or the like), any combination thereof, and/or other like materials; composites and/or other like materials; metals, such as zinc, magnesium, titanium, copper, iron, steel, carbon steel, alloy steel, tool steel, stainless steel, aluminum, any combination thereof, and/or other like materials; alloys, such as aluminum alloy, titanium alloy, magnesium alloy, copper alloy, any combination thereof, and/or other like materials; any other suitable material; and/or any combination thereof.

Furthermore, the components defining the above-described pressurized fluid cutting system 100 and corresponding sensor-based active diagnostics system 400 embodiment(s) may be purchased pre-manufactured or manufactured separately and then assembled together. However, any or all of the components may be manufactured simultaneously and integrally joined with one another. Manufacture of these components separately or simultaneously may involve extrusion, pultrusion, vacuum forming, injection molding, blow molding, resin transfer molding, casting, forging, cold rolling, milling, drilling, reaming, turning, grinding, stamping, cutting, bending, welding, soldering, hardening, riveting, punching, plating, 3-D printing, and/or the like. If any of the components are manufactured separately, they may then be coupled with one another in any manner, such as with adhesive, a weld, a fastener (e.g. a bolt, a nut, a screw, a nail, a rivet, a pin, and/or the like), wiring, any combination thereof, and/or the like for example, depending on, among other considerations, the particular material forming the components. Other possible steps might include sand blasting, polishing, powder coating, zinc plating, anodizing, hard anodizing, and/or painting the components for example.

While this disclosure has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the present disclosure as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the present disclosure, as required by the following claims. The claims provide the scope of the coverage of the present disclosure and should not be limited to the specific examples provided herein. 

1-20. (canceled)
 21. A method of operating a high pressure system, the method including: detecting at least one acoustic emission generated by a defect in a component of the high pressure system, wherein the at least one acoustic emission is detected by an acoustic sensor attached to the high pressure system; processing a signal sent from the acoustic sensor in response to the at least one acoustic emission thereby generating a processed signal; analyzing the processed signal; and predicting failure of the high pressure system based at least in part on the analysis of the processed signal.
 22. The method of claim 21 wherein analyzing the processed signal includes identifying at least one characteristic of the defect that generated the acoustic emission.
 23. The method of claim 21, wherein identifying at least one characteristic of the defect that generated the acoustic emission includes at least one of: identifying a type of the defect; identifying a size of the defect; identifying a change in the size of the defect; and identifying a location of the defect.
 24. The method of claim 21 wherein the acoustic sensor is a first acoustic sensor, and the at least one acoustic emission is detected by the first acoustic sensor attached to the high pressure system and a second acoustic sensor attached to the high pressure system.
 25. The method of claim 24 wherein the first acoustic sensor is attached to a first component of the high pressure system, and the second acoustic sensor is attached to a second component of the high pressure system.
 26. The method of claim 25 wherein the first component is a pressure vessel capable of withstanding internal pressures of greater than 2,000 psi, and the second component is an end cap abutting the pressure vessel.
 27. The method of claim 21, further comprising attaching the acoustic sensor to the high pressure system.
 28. A method of performing maintenance on a high pressure system, the method including: detecting a first acoustic emission generated by the high pressure system at a first time; processing the first acoustic emission to establish a baseline; subsequent to detecting the first acoustic emission, detecting a second acoustic emission generated by the high pressure system at a second time; processing the second acoustic emission to establish a current data set; and comparing the baseline to the current data set to determine if a defect occurred in the high pressure system between the first time and the second time.
 29. The method of claim 28 wherein the first acoustic emission and the second acoustic emission are detected by at least one acoustic sensor.
 30. The method of claim 29, further comprising attaching the at least one acoustic sensor to at least one component of the high pressure system.
 31. The method of claim 29 wherein the at least one acoustic sensor includes a first acoustic sensor and a second acoustic sensor, and the method further comprises estimating a location of the defect based, in part, on positions of the first and second acoustic sensors.
 32. The method of claim 28, further comprising analyzing the current data set thereby identifying the type of defect. 